Apparatus for Positioning and Operating Upon a Construct

ABSTRACT

An apparatus for operating upon a construct. In one example, the apparatus comprises a tool, a feed path for a feed path for feeding the construct to and withdrawing the construct from the tool, and a positioning mechanism. The positioning mechanism comprises an arm positioned proximate to the tool and a guide for directing the construct toward the tool. The arm is movable between a guiding position and a withdrawn position, and the guide is mounted to the arm for moving with the arm so that the guide is at least partially disposed in the feed path when the arm is in the guiding position. A recess is defined in the tool for at least partially accommodating the guide.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.12/980,472, filed Dec. 29, 2010, which claims the benefit of U.S.Provisional Patent Application No. 61/335,040, filed Dec. 30, 2009, bothof which are incorporated by reference herein in their entirety.

BACKGROUND OF THE DISCLOSURE

The present disclosure relates to tools and methods for formingmaterials into articles, elements, constructs, or containers that may beused to hold, contain, or prepare food products or other products.

SUMMARY OF THE DISCLOSURE

In one aspect, the disclosure is generally directed to an apparatus foroperating upon a construct (e.g., a bowl, tray, plate, or any othersuitable type of container (e.g., a press-formed paperboard container)or support). In one example, the apparatus comprises a tool, a feed pathfor feeding the construct to and withdrawing the construct from thetool, and a positioning mechanism. In one example, the positioningmechanism comprises an arm positioned proximate to the tool and a guidefor directing the construct toward the tool. The arm is movable betweena guiding position and a withdrawn position, and the guide is mounted tothe arm for moving with the arm so that the guide is at least partiallydisposed in the feed path when the arm is in the guiding position. Arecess is defined in the tool for at least partially accommodating theguide.

In general, another aspect of the disclosure is directed to a method ofusing an apparatus comprising a tool to operate upon a construct. Themethod comprises moving a positioning mechanism into a guiding position,in which at least a portion of the positioning mechanism is in a feedpath of the apparatus. The tool defines a recess for at least partiallyaccommodating at least a portion of the positioning mechanism. Themethod further includes feeding a construct along the feed path into theapparatus, and guiding the construct in the tool with at least a portionof the positioning mechanism.

In accordance with one aspect of this disclosure, the above-discussedapparatus, method, aspects, and/or features, in various combinationsand/or subcombinations, may be integrated into a system that makespress-formed paperboard containers

Those skilled in the art will appreciate the above stated advantages andother advantages and benefits of various additional embodiments readingthe following detailed description of the embodiments with reference tothe below-listed drawing figures.

According to common practice, the various features of the drawingsdiscussed below are not necessarily drawn to scale. Dimensions ofvarious features and elements in the drawings may be expanded or reducedto more clearly illustrate the embodiments of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are schematic cross-sectional views of a tool accordingto one embodiment of the disclosure.

FIG. 2 is an isometric view of a lower assembly of an apparatusaccording to one embodiment of the disclosure.

FIG. 3 is an isometric view of an upper assembly of the apparatusaccording to one embodiment of the disclosure.

FIG. 4 is an isometric view of a positioning mechanism according to oneembodiment of the disclosure.

FIG. 5 is a top view of the positioning mechanism of FIG. 4.

Corresponding parts are designated by corresponding reference numbersthroughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present disclosure relates generally to various aspects ofmaterials, packages, elements, articles, containers (e.g., press-formedpaperboard containers) and methods of making such materials, packages,elements, articles and containers. Although several different features,aspects, implementations, and embodiments are provided, numerousinterrelationships between, combinations thereof, and modifications ofthe various features, aspects, implementations, and embodiments of thedisclosure are contemplated hereby. In one illustrated embodiment, thepresent disclosure relates to forming a container for heating or cookingfood items, such as in a microwave oven. However, in other embodiments,the disclosure can be related to forming articles or containers that arenot used for microwave cooking.

The present disclosure includes a forming tool 1 for at least partiallycontaining and operating upon (e.g., at least partially forming) acontainer (e.g., schematically shown in the drawings as a construct C)suitable for use in heating or cooking a food item. For example, thecontainer or construct C may be a press-formed paperboard container, orany other suitable type of container or construct. For example, thecontainer may be similar to the containers disclosed in the followingU.S. patents and U.S. patent applications: U.S. Pat. No. 7,365,292; U.S.Pat. App. Pub. Nos. 2005/0109653; 2008/0047958; and 2007/0262487, thedisclosures of the above-noted documents being entirely incorporated byreference herein for all purposes. Also, the forming tool 1 of thepresent disclosure can have similar features as any of the variousforming tools and forming features disclosed in the above-identifiedpatents and published patent applications.

In the illustrated embodiment, a tool assembly or apparatus includes theforming tool 1 and a positioning mechanism 13 mounted on the formingtool or in any other suitable location. As shown in FIGS. 1A and 1B, theforming tool 1 includes an upper (first) tool assembly 3 and a lower(second) tool assembly 5. In one example, the forming tool 1 is a moldassembly, wherein the upper tool assembly 3 and the lower tool assembly5 are molds (e.g., a concave mold and a convex mold) that define achamber therebetween for containing and molding or otherwise operatingon the construct. The upper and lower tool assemblies 3 and 5 areindependently moveable in the vertical direction along a central axis Aof the tool to form (e.g., at least partially form) a blank or otherconstruct into the three-dimensional container or any other suitableconstruct. In the illustrated embodiment, the forming tool 1 is thesecond forming tool in a two-step process of forming a paperboard blankinto a three-dimensional container or other construct. The blank isoptionally partially formed into the container in a preceding formingtool 100 (shown schematically in FIGS. 1A and 1B) and is transferred tothe forming tool 1 along a feed path 102 for final forming (e.g., finalrolling of the edge of the top flange of the container or other formingprocess). The blank, partially-formed container, fully-formed container,or any other construct C can translate along the feed path 102 from thepreceding forming tool 100 into an inlet end 104 of the forming tool 1,and out through an outlet end 106 of the forming tool (FIG. 1A). In analternative embodiment, the construct C can be fed into the tool 1 froma magazine of constructs, a hopper, or any other apparatus.

As shown in FIGS. 2 and 3, the upper and lower tool assemblies 3, 5 areconfigured to accommodate a container having a generally oval-shapedbottom wall and upwardly extending side walls that form a generallyoval-shaped cavity of the container. The upper and lower forming toolassemblies 3, 5 could be otherwise configured to accommodate or formcontainers or other constructs having other three-dimensional shapes(e.g., a container with circular-shaped cavity, rectangular-shapedtrays, etc.). After being formed from the blank in the forming tool 1,the container can be discharged from the forming tool and can be furtherhandled, package, or subjected to additional forming or shapingprocesses without departing from the scope of this disclosure.

As shown in FIG. 2, the lower tool assembly 5 has a lower support plate9 and a lower forming plate 11 mounted on the support plate. In theillustrated embodiment, the lower forming plate 11 has features 12 forforming the container. The lower tool assembly 5 could be otherwiseshaped, arranged, and/or configured without departing from thedisclosure. The positioning mechanism 13 can be mounted to a side of thelower forming plate 11 and can be positioned adjacent or proximate tothe outlet end 106 of the forming tool 1. The positioning mechanism 13comprises a positioning member or guide 15 connected to an arm 17. Inthe illustrated embodiment, the arm 17 is connected to an actuator 19,which can be connected to an actuator mounting plate 21 that connectsthe actuator to the lower tool assembly 5 such as with mechanicalfasteners or adhesives. A proximity switch mounting plate 25 is locatedon top of the actuator mounting plate 21 and adjacent to the arm 17. Inthe illustrated embodiment, the proximity switch mounting plate 25 isfor positioning two proximity switches 27, 29 that detect the positionof the arm 17. In one embodiment, the actuator 19 is apneumatically-operated, rotary cylinder actuator, but the actuator couldbe any other type of actuator without departing form the disclosure. Forexample, the actuator could be a linear actuator, or it could be poweredby an electric motor.

As shown in FIGS. 2, 4, and 5, the arm 17 can be connected to an axle 19a of the actuator 19 at a pivot end 17 a. The guide 15 can be mounted toa guide end 17 b of the arm 17 by mechanical fasteners, adhesive, orotherwise. The guide end 17 b can be curved so that the guide 15 isgenerally perpendicular to the movement of the constructs C along thefeed path 102, as described below, when the positioning mechanism 13 isin the guiding position (FIG. 2). The guide 15 can include a guidesurface 15 a that contacts the construct C as described below. The guidesurface 15 a can be shaped to correspond to the shape of the constructformed by the apparatus. For example, the guide surface 15 a can becurved (FIG. 4) in order to correspond to a construct with a curvedwall. Alternatively, the guide surface 15 a can be flat to engage aconstruct with a flat, vertical wall, in another example. The mountingplate 21 can be angled away from the lower forming plate 11 and the feedpath 102 to allow the arm 17 and guide 15 to move completely out of thefeed path 102 when the positioning mechanism 13 is moved to thewithdrawn position. The positioning mechanism 13 could be otherwiseshaped, arranged, and/or configured without departing from thedisclosure.

As shown in FIG. 3, the upper tool assembly 3 includes an upper supportplate 41 and an upper forming plate 43 mounted to the upper supportplate. FIG. 3 shows the upper tool assembly 3 in an inverted position toshow the contour of the bottom surface 45 of the upper forming plate 43.In the illustrated embodiment, the upper forming plate 43 has containerforming features (e.g., a cavity 47) formed in the bottom surface 45. Inone embodiment, the features 12 on the lower tool assembly 5 and thefeatures 47 on the upper tool assembly 3 are complimentary in shape tofurther form the container from the blank. In one embodiment, thefeatures 12, 47 can be shaped, arranged, and positioned to roll the edgeof a top flange of a container formed in the tool 1. In the illustratedembodiment, the upper tool assembly 3 includes a cavity or recess 49 atone end of the upper forming plate 43 and adjacent to the features 47.The recess 49 opens outwardly (e.g., opens away from the features 47toward the outlet end 106 of the forming tool 1) for accommodating theguide 15 when the upper tool assembly 3 and lower tool assembly 5 areclosed or at least partially closed. The upper tool assembly 3 could beotherwise shaped, arranged, and/or configured without departing from thedisclosure.

A method of forming the container from the blank according to oneembodiment is described below, wherein the blank, container, orpartially-formed container is generally referred to as a construct C.The container of the present disclosure can be formed from the blank byfeeding the blank into the preceding forming tool 100 and pressing andshaping the blank into a partially-formed container or other constructby operating the preceding forming tool 100. Next, the construct istransferred to the forming tool 1, which can be a second forming toollocated in-line with a first forming tool, or the forming tool 1 can beother than the second forming tool (e.g., first, third, etc.). In oneembodiment, after a construct C exits the preceding forming tool 100such as by being ejected by a puff of air or by a pick-and-placeapparatus, the construct can translate along the feed path 102 to theinlet end 104 of the forming tool 1. The construct C can travel betweenstages on a chute or slide under the force of gravity. Alternatively,the construct can be transported between the stages on any conveyor,such as rollers, a belt, etc., or the construct can be manually insertedinto the forming tool 1.

When the upper tool assembly 3 and lower tool assembly 5 are separatedin an open position (FIG. 1A), the partially formed container cancontinue along the feed path 102 through the inlet end 104 onto thelower forming plate 11. The positioning mechanism 13 is actuated toposition the arm 17 and the guide 15 in the guiding position generallyshown in FIG. 2 so that the guide 15 is blocking a portion of the feedpath 102 adjacent the forming features 12 of the lower forming plate 11.The positioning mechanism is positioned in the guiding or “stop”position (FIG. 2) to guide the construct C relative to the formingfeatures 12 of the lower tool assembly 5. The construct C can continuetranslating along the feed path 102 across the lower forming plate 11until the construct contacts or otherwise engages, the guide surface 15a of the guide 15, which stops the forward progress of the construct inthe feed path onto the forming features 12. After the construct hascontacted the guide 15, the actuator 19 of the positioning mechanism 13is actuated to position the positioning mechanism to the “withdrawn”position (FIGS. 4 and 5). In one embodiment, one or both of the uppertool assembly 3 and the lower tool assembly 5 can be moved toward aclosed position (FIG. 1B) after the positioning mechanism 13 is actuatedand before the guide 15 has reached the withdrawn position.Alternatively, the tool 1 can be closed prior to moving the positioningmechanism 13 to the withdrawn position. The location of the recess 49 inthe upper forming plate 43 of the upper tool assembly 3 preventsinterference of the guide 15 and arm 17 with the upper forming plate asthe forming tool 1 closes. For example, FIG. 1B schematically shows theforming tool 1 in a generally closed position with the guide 15partially received or contained in the recess 49. In an alternativeembodiment, the forming tool 1 can be actuated and moved toward theclosed position after the guide 15 has been completely positioned in thewithdrawn position.

The positioning mechanism 13 and other aspects of the forming tool 1 andthe preceding forming tool 100 can be controlled by one or moreprogrammable logic controllers (PLC) 108 (FIGS. 1A and 1B) or any othersuitable type of controller. The PLC 108 can receive signals from thetwo proximity switches 27, 29 to determine if the guide 15 is in theguiding position or the withdrawn position. The proximity switch 27detects when the guide 15 is in the guiding position, and the proximityswitch 29 detects when the guide is in the withdrawn position. Thetiming of the opening and closing of the forming tool 1, the pivoting ofthe arm 17 and guide 15 between the guiding and withdrawn positions, andthe ejecting of the construct C can be adjusted and optimized accordingthe equipment and conveyors used and the configuration of the same.

In an exemplary embodiment, wherein the forming tool 1 is in the openposition of FIG. 1A, the PLC 108 instructs the actuator 19 to pivot thearm 17 until the guide 15 is in the guiding position (FIG. 2) and thearm 17 contacts the proximity switch 27. The PLC 108 then instructs thepreceding tool 100 to eject a construct C, which then travels ortranslates along the feed path 102 in a conventional manner. Then, theconstruct is stopped or intercepted by the guide 15 as described above.The PLC 108 then instructs the forming tool 1 to move to the closedposition, and, as the forming tool is closing, the guide 15 can be atleast partially accommodated in the recess 49 (shown schematically inFIG. 1B). The PLC 108 can instruct the actuator 19 to pivot the arm 17to the withdrawn position before instructing the forming tool 1 toclose, as the forming tool is closing, or after the forming tool ismoved to a fully closed position, wherein the forming features 12, 47operate on the construct. When the arm 17 engages the proximity switch29, which is adjacent the withdrawn position of the positioningmechanism 13 (FIG. 5), the PLC 108 instructs the forming tool 1 to moveto the open position (FIG. 1A) and eject the construct C, such as with apuff of air. The construct C can then proceed downstream through theoutlet end of the forming tool 1 along the feed path 102 in aconventional manner. The construct C can be further conveyed in thedownstream direction along the feed path 102 by a conveying mechanism(e.g., conveyor belt) for further processing, packaging, and/or shipmentor for assembly into a finished food product package. The positioningmechanism 13 and the forming tool 1 can be operated in alternativeoperating steps, methods, or sequence without departing from thedisclosure.

In one embodiment, the upper tool assembly 3 and the lower tool assembly5 can be mounted at approximately a 45° angle in a machine (not shown)of the type manufactured by Peerless Machine & Tool Corporation inMarion, Ind., USA. The machine provides the primary compressive forcesto sufficiently close and open the tool assemblies 3, 5 of the presentdisclosure. The closing and opening of the tool assemblies 3, 5 by themachine forms the three-dimensional articles or containers. In othertypes of machines, the tool assemblies 3, 5 may be revised/modified topermit the tool assemblies to operate in alternative orientations (e.g.,upside down or on their side). It should be understood that theoperating position of tool assemblies 3 and 5 shown and/or describedherein is not intended to limit the scope of the disclosure.

In accordance with the exemplary embodiment of the present disclosure,the container can optionally include microwave interactive material thatmay comprise a microwave interactive element such as a susceptor. Thecontainer can include microwave interactive elements or material as isdisclosed in any of the U.S. patents and Published patent applicationsthat are noted above and incorporated by reference herein.Alternatively, the microwave interactive material can comprise any othertype of microwave interactive elements, materials, and/or variouscombinations of microwave interactive elements and material, asdiscussed in greater detail below. The microwave interactive elementsand materials may be omitted from the container without departing fromthe scope of this disclosure.

In accordance with one embodiment of this disclosure, theabove-discussed aspects, features and methods of this disclosure,various combinations thereof, and/or various subcombinations thereof,are integrated into a system (e.g., a set of tools) that makespress-formed paperboard containers, such that the construct C is apress-formed paperboard container and/or a precursor thereof. The systemmay be conventional, except for incorporating the above-discussedaspects, features and methods of this disclosure, various combinationsthereof, various subcombinations thereof, and/or any other modificationsthat would be understood by one of ordinary skill in the art in view ofthis disclosure. The combination of the forming tool 1 and positioningmechanism 13, which may be cooperatively associated with a controller(e.g., PLC 108) and/or other respective aspects, features and methods ofthis disclosure, provides a very useful, accurate and reliable additionto, for example, the reciprocating tools for press-forming paperboardcontainers or any similar articles that are made in a similar way, orthe like.

The foregoing description of the disclosure illustrates and describesvarious exemplary embodiments. Various additions, modifications,changes, etc., could be made to the exemplary embodiments withoutdeparting from the spirit and scope of the disclosure. It is intendedthat all matter contained in the above description or shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense. Additionally, the disclosure shows and describes onlyselected embodiments of the disclosure, but the disclosure is capable ofuse in various other combinations, modifications, and environments andis capable of changes or modifications within the scope of the inventiveconcept as expressed herein, commensurate with the above teachings,and/or within the skill or knowledge of the relevant art. Furthermore,certain features and characteristics of each embodiment may beselectively interchanged and applied to other illustrated andnon-illustrated embodiments of the disclosure.

It will be understood by those skilled in the art that while the presentdisclosure has been discussed above with reference to exemplaryembodiments, various additions, modifications and changes can be madethereto without departing from the spirit and scope of the invention asset forth in the claims.

What is claimed is:
 1. An apparatus for operating upon a construct, theapparatus comprising: a tool; a feed path for feeding the construct toand withdrawing the construct from the tool; and a positioning mechanismcomprising: an arm positioned proximate to the tool, wherein the arm ismovable between a guiding position and a withdrawn position; a guide fordirecting the construct toward the tool, wherein the guide is mounted tothe arm for moving with the arm so that the guide is at least partiallydisposed in the feed path when the arm is in the guiding position; and arecess defined in the tool for at least partially accommodating theguide.
 2. The apparatus of claim 1, wherein the arm is mounted to anactuator for moving the arm between the guiding position and thewithdrawn position, and the actuator is mounted to a mounting plate. 3.The apparatus of claim 2, wherein the tool comprises a first formingplate and a second forming plate, and the mounting plate is mounted toat least one of the first and second forming plates.
 4. The apparatus ofclaim 3, wherein at least one of the first and second forming plates ismovable toward and away from the other for moving the at least one ofthe first and second forming plates between an open position and aclosed position.
 5. The apparatus of claim 4, wherein the recess isdefined in the first forming plate, and the mounting plate is mounted tothe second forming plate.
 6. The apparatus of claim 5, wherein the firstforming plate is movable between the open and closed positions.
 7. Theapparatus of claim 3, wherein the positioning mechanism comprises atleast one proximity switch proximate at least one of the guidingposition and the withdrawn position of the arm.
 8. The apparatus ofclaim 2, wherein the actuator is a rotary actuator and the arm ismounted to the rotary actuator at one end of the arm so that the rotaryactuator is operable to pivot the arm between the guiding position andthe withdrawn position of the arm.
 9. The apparatus of claim 1, whereinthe guide comprises a curved portion for engaging a construct having acurved side.
 10. An apparatus for operating upon a construct supplied byway of a feed path, the apparatus comprising: a guide mounted for beingmoved between a withdrawn position, in which the guide is at leastpartially withdrawn from the feed path, and a guiding position, in whichthe guide is at least partially positioned in the feed path; and a toolpositioned along the feed path for being at least partially closed uponthe construct to at least partially contain and operate upon theconstruct, wherein the tool includes a recess for at least partiallycontaining the guide while simultaneously the guide is in the guidingposition, and the tool is at least partially closed upon, and at leastpartially contains, the construct.
 11. A tool for at least partiallyforming a construct, the tool comprising: a mold assembly comprisingmolds between which there can be relative movement for opening and atleast partially closing a chamber cooperatively defined by the molds,the chamber being for at least partially containing and operating uponthe construct; and at least one of the molds further defines a recessthat is outwardly open while the mold assembly is in a closedconfiguration.
 12. The tool according to claim 11, wherein the recesscomprises a sidewall that is curved according to the shape of thechamber and two end walls that are spaced apart to accommodate a widthof a guide portion of a positioning mechanism, the positioning mechanismbeing operable to position at least a portion of the guide portionwithin the recess.
 13. The tool according to claim 11, wherein: thechamber is at least partially defined by a cavity of a first mold of themolds; a guide is mounted to the first mold for moving between withdrawnand guiding positions; as compared to the withdrawn position, the guideis closer to the cavity of the first mold while the guide is in theguiding position; a second mold of the molds at least partially definesthe recess; and the recess being adapted for at least partiallycontaining the guide while simultaneously the guide is in the guidingposition, and the mold assembly is at least partially closed upon, andat least partially contains, the construct.